Chemical reactors

The objective of this project was to create a machine to functions both as a reaction chamber and a pump. The nature of the reaction demands that certain conditions be met for the mixture to react. The reaction occurring at the heart of the machine is of such intensity and abrasiveness that materials and casting processes had to be researched to produce parts that could survive long enough for the machine to be profitable. Easy maintenance was another design objective, especially because the parts of the machine exposed directly to the reaction have a higher failure rate. The design has undergone several iterations as each prototype yielded test data that helped fix shortcomings and design flaws. More than 2 dozen of these machines are currently working in plants around the world and more are expected to be made in the near future.

Adjusting the design.

For cost effectiveness and time, most parts are casted then machined. The parts in direct contact with the reaction require special heat treatment before and after machining to achieve the required hardness.

One of the most complex parts to cast were the stainless steel nozzles.

Design of test rig.

Testing rig unplugged.

Reactor turbine connected to the testing rig and ready for the first trial run.

second prototype waiting for tests.

Ready for shipping.

As the design was finalized, a spinoff project began to take off, this time, the design would integrate other aspects of the plant into a single unit, this to assure that any leaks in the reaction chamber could be contained safely and to prevent heat loss in the reaction mixture.

Before even considering modeling parts in Inventor, ideas were sketched and developed on paper. The first idea was to use components we had already developed for the original reactor. From top left to bottom right: the evolution of the design.